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Bunge is a U.S.-based agribusiness and food ingredient manufacturer that is working to improve the global food supply chain. They were looking for a complete and convenient way to achieve on-demand flow in the operation/process of filling rice bran into full containers. After reviewing options, they decided to implement the "AirSweep System" and installed four "AirSweep VA-06 units" at a 90-degree angle on the sloped walls of the rice bran containers. As a result, they confirmed significant improvements in material flow and worker safety. *For more details, please refer to the PDF document or feel free to contact us.*
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A major manufacturer of food, food ingredients, and flavor products in the United States uses ribbon blender machines for custom mixing by ingredient batch. The company has manufacturing facilities in 25 countries around the world and was looking for ways to improve the discharge process between custom batches of raw materials. To this end, they experimentally installed eight "VA-12-TRI-TRI units" on the ribbon blender and associated hopper, aiming to streamline the cleaning process, with four units positioned on both sides of the blender, about 0.3 meters above the bottom. As a result, the company reduced the amount of flour washed away by 62% and decreased labor by 42%. *For more details, please refer to the PDF document or feel free to contact us.
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For pet food manufacturers, avoiding cross-contamination is central to the manufacturing process. "Bulk material flow issues," such as rat holes, bridging, and other material blockages, reduce the flow of materials through the processing system and increase the likelihood of cross-contamination. In 2018, research was conducted to replace the ineffective material activation system in use at the time with a new system, planning the introduction of "AirSweep." By converting pet food ingredients from vibrators and air-powered hammers to this unit, the processing system has become more efficient and safe in its flow. *For more details, please refer to the PDF materials or feel free to contact us.*
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Alumina-based industrial mineral processors handle over 120,000 tons of materials annually for the refractory and abrasive industries. The rapid transfer of processed materials from storage containers to bulk bags has been an ongoing issue regarding brand identity guidelines at the factory. Therefore, a trial run was conducted for the pneumatic flow assistance system, "AirSweep System," designed to provide on-demand bulk material flow. As a result, the product eliminated all blockages near the container outlet, reduced the filling time of bulk bags from 1 hour to 2 minutes, and improved productivity by 3000%. *For more details, please refer to the PDF document or feel free to contact us.
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To manufacture products of superior quality, international major paint and coating manufacturers needed to use a new grade of titanium dioxide (TiO2). The new material consists of finer and lighter particles, which tend to form bridges over the vibration feeder system already installed in the storage silos. Therefore, the feeder was replaced with a live bin bottom, and four "VA-12 (1-1/2") AirSweep units" were installed approximately 60 cm above the live bottom. By solving process issues using this system, we are producing high-quality products while achieving a production capacity greater than expected. *For more details, please refer to the PDF document or feel free to contact us.*
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A major coal-fired power plant in the Midwest of the United States needed to meet federal emissions standards while maximizing power output. To achieve this, the plant installed a Dry Sorbent Injection (DSI) system designed to reduce emissions of hydrochloric acid and sulfur dioxide. However, DSI technology relies on poorly flowing bulk solid materials such as hydrated lime, trona, soda ash, and sodium bicarbonate. Therefore, a "VA-51 AirSweep" was installed in the trough of the screw conveyor. As a result, the power plant has been continuously operational since the fall of 2015, with no compliance issues, thanks to the support of the DSI system and the Airsweep material activation system. *For more details, please refer to the PDF document or feel free to contact us.*
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The Scrubgrass power plant in Venango County, Pennsylvania, generates electricity using a byproduct of mining, known as asphalt waste coal. With advanced environmental control technology, this coal is utilized as a clean energy source. In 2003, the Scrubgrass power plant was facing issues with coal transportation and was seeking solutions to resolve chute blockages. The company installed two "Airweep (model VA-51) units" on the chute leading to the hammer mill. After running continuously during a 12-hour shift, there were no occurrences of chute blockages at all. *For more details, please refer to the PDF document or feel free to contact us.*
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"AIRSWEEP" is a new method for completely controlling the first-in, first-out flow of powder and resolving blockages. With a kit available, it can be easily installed from the outside of the container. It lifts the powder along the walls of the container using compressed air. A typical system consists of an AirSweep nozzle, solenoid valve, controller, air tank, etc., and the compressed air (gas) usage is only 0.28m3/min. 【Features】 ■ Easy installation from the outside of the container with an available kit ■ Specially shaped nozzle (patented) ■ Composed of AirSweep nozzle, solenoid valve, controller, air tank, etc. ■ The compressed air (gas) usage of a typical system is only 0.28m3/min ■ Uses compressed air or gas at 0.5 to 0.7Mpa *For more details, please refer to the PDF document or feel free to contact us.
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This catalog is the new catalog (2020 edition) of ROSS machine safety solutions. As a company specializing in fluid machine safety, we provide explanations regarding standards for hydraulic and pneumatic machine safety, safety requirements of those standards, the process of building machine safety, and case studies on risk assessment and risk reduction methods. Additionally, you can find information on globally recognized safety function types and risk reduction methods, along with our solutions, specifications of each product, and application circuit examples. [Contents (partial)] ■ Safety proposed by ROSS ■ Safety proposed by ROSS ■ Applicable machine safety standards ■ Safety requirements ■ Machine safety construction process *For more details, please refer to the PDF document or feel free to contact us.
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This is a poppet-type solenoid valve with high durability and high responsiveness. By rapidly turning the poppet solenoid valve ON/OFF, it is possible to intermittently blow air (cooling) and significantly reduce the amount of compressed air used. By accurately controlling the frequency (the number of ON/OFF cycles per second) and the duty cycle (the ratio of ON to OFF), it is possible to maintain sufficient blowing force required for the application while reducing compressed air usage by more than 50%. Additionally, our poppet valves are not disposable. We sell internal component sets such as O-rings and pistons, so by replacing worn parts, you can continue to use the main unit. The size of the pulse blow valve is wide-ranging, with options available up to super large diameter (65A)!
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Many manufacturers store and retrieve various substances in containers such as hoppers, but due to the shape of the hopper and the nature of the substances, a clogging issue known as bridging occurs near the outlet. Currently, equipment such as air knockers and air vibrators are used to strike or shake the hopper, but while the noise is loud, the effectiveness is limited, resulting in workers having to regularly (or when a clog occurs) go to the site and hit the hopper with hammers or sticks. The completely new proposal that uses compressed air to fully resolve issues like bridging and rat-holing is AirSweep. Examples of resolved substances: aluminum, coal, copper, diatomaceous earth, gypsum, iron ore, limestone, magnetite, phosphates, shale, soda ash, activated carbon, adipic acid, aluminum chloride, boric acid, chlorine, herbicides, hydrated lime, iron oxide, polyacrylamide, titanium dioxide, zinc, animal feed, brewing grains, cocoa, coffee, corn, wheat, hops, salt, edamame, spices, sugar, starch, acetate, cement, chalk, cork, detergents, fertilizers, fly ash, pharmaceuticals, plastics, polymer resins, wax flakes, wood chips, etc.
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Features & Benefits: • Closed center valve function - Complete control of double-acting cylinders (including inching function and load holding function) • Redundant control via position feedback - Can be compliant with Category 4/PL e when used with appropriate safety controls • External monitoring type - Enables complete safety control and feedback monitoring of the cylinder control circuit • Intermediate position sensing - For detecting safe closed center positions • ROSS poppet technology - High-speed operation, high reliability, contamination resistance, surface sealing, low friction • Solenoid LED indicator - Assists in troubleshooting
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Content of the scene A valve with a monitoring device performs 1) fault detection, 2) output of fault signals, and 3) prevention of restart when a failure occurs on one side. In particular, 3) ensures that the valve does not operate even if power is supplied during a fault, thereby ensuring the safety of the operator. With monitoring, the operator is freed from checking for air leaks and can focus on more productive tasks.
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Scene content As usual, the press operation was underway, but one side of the valve had already malfunctioned. The operator continued to operate without noticing the signs of one-sided failure (air leakage from the exhaust port)... When the power to the valve was turned OFF, both valve bodies failed, resulting in none of the valves closing, which meant that secondary air could not be exhausted, and the press would not stop. The operator could face a "pinching accident."
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Scene content: Inside the double valve, two valve bodies repeatedly open and close almost simultaneously. When one side does not close (failure) after the valve is turned off, the valve body on the functioning side closes, and the secondary side air is exhausted, causing the press to stop. However, the double valve can still operate if power is restored even when one side is malfunctioning. Air leakage occurs from the valve's exhaust port, but this "failure indication" is difficult to notice.
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Content of the scene: A solenoid valve (power control element) was installed to ensure safety through a redundant structure and cross-checking (mutual monitoring) in a dual-channel system. Therefore, even in a situation where one valve body was broken and could not shut off the hydraulic pressure, the other valve body operated normally, shutting off the hydraulic pressure and returning it to the tank, allowing the operator to safely complete the mold change.
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Content of the scene After conducting a risk assessment of the machinery, the failure of the power control element (cylinder control valve) was determined to be a significant risk. It is necessary to introduce products that meet the high safety requirements corresponding to the category/performance level. The introduced valve is a highly reliable, dual-channel redundant valve that ensures power (hydraulic) is reliably cut off even if the hydraulic cylinder control valve fails. In conjunction with the interlock, it cuts off the supply pressure and returns the power (hydraulic) of the moving mold to the tank, allowing the operator to safely perform mold changes.
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Scene content: While the machine operator opened the interlocked door to change the mold and was cleaning the mold, the moving mold, which was supposed to stop due to the interlock mechanism, slowly and quietly moved towards him without him noticing. By the time the machine operator realized this... as a result, he suffered severe injuries, having a part of his body caught and severed by the mold.
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Scene content The cylinder control valve has been changed to a "double valve." At this time, if the return position of the cylinder is set to the "upper end," even if one side of the double valve fails, the functioning side of the valve body will operate to return the cylinder to the set position. By doubling the pneumatic energy control (double valve configuration) and using an optical safety device, we can avoid accidents involving workers being caught.
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Scene content: The operator was unable to set the workpiece properly due to carelessness. There is an optical safety device, so even if the neighboring operator adjusts the workpiece by hand, the machine should stop... The 'valve' controls the rise and fall of the pneumatic cylinder. If the valve fails, even if the safety device operates, the air cannot be switched, and the cylinder will not stop.
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Scene content: A machine maintenance technician performing regular machine maintenance during the Golden Week. Following company rules, they search for the residual pressure relief valve to shut off all power energy to the machine, cut off the supply air, and begin venting the residual pressure air in the piping. With a typical ball valve, it takes much longer than expected to vent all the residual pressure air in the piping. If one approaches the machine with the mindset of "Well, as long as it's mostly vented, it's okay," the compressed air that is still present may suddenly cause the cylinder to move.
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Scene content: A malfunction has occurred in the manufacturing of a certain product. It is necessary to immediately check the condition of the machinery, and to do so, all power energy that operates the machinery must be shut off. I received instructions to respond urgently. Shortly after joining the company, I learned which one is the shut-off exhaust valve during training, but I don’t remember... The general three-way valve and the shut-off exhaust valve look similar; which one should I shut off?
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This document introduces the "Labor Safety and Health Act," which serves as the foundation for protecting workplace environments. The "Labor Safety and Health Act," established in 1972, aims to ensure the safety and health of workers in the workplace and promote the creation of a comfortable work environment by implementing comprehensive and planned measures to prevent labor accidents. This includes establishing hazard prevention standards, clarifying responsibility systems, and promoting voluntary activities in conjunction with the Labor Standards Act. Additionally, it includes information on the "Labor Accident Prevention Plan," which outlines key areas the government is focusing on to reduce labor accidents. [Contents] ■ About the "Labor Safety and Health Act" ■ About the "Labor Accident Prevention Plan" *For more details, please refer to the PDF document or feel free to contact us.
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Among the four items that determine the Performance Level (PL) of ISO13849-1, there is the category (Categories). It is divided into five levels: B, 1, 2, 3, and 4, according to the specified architecture, with the required safety functions becoming stricter at each level. This is a simplified (informal) method to understand the safety levels of the specified architecture. In this document, we will convey a simple way to understand the surface aspects of this safety category using airplanes. [Contents] ■ Category B ■ Category 1 ■ Category 2 ■ Category 3 ■ Category 4 *For more details, please refer to the PDF document or feel free to contact us.
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This document introduces various features of world-class monitored double valves. The control valves mounted on press machines in primarily metal pressing factories must have a safe mechanism, as they are responsible for the ON/OFF operation of the press machines. Our company offers a variety of double valves that boast world-class safety performance. It is also possible to install monitors on existing double valves, so please feel free to consult with us. [Contents] ■ Why are monitored double valves safe? ■ Improvement of cost performance and consideration for the environment *For more details, please refer to the PDF document or feel free to contact us.
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This document introduces the relationship between product reliability and MTTF (Mean Time to Failure). MTTF is often used as an indicator to understand the lifespan of a product. If the MTTF of a product is known, one can grasp the average lifespan of that product. Additionally, while utilizing MTTF as one of the indicators, it is important to be aware that theoretically, there is approximately a 63% probability of failure occurring before reaching the MTTF. [Contents] ■ Reliability indicating the probability of the product operating ■ Relationship between MTTF and reliability ■ Reference URL *For more details, please refer to the PDF document or feel free to contact us.
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This document introduces MTTF (Mean Time to Failure), which represents the lifespan of a product. Since MTTF is used for products that cannot be repaired, it has the same meaning as the so-called average lifespan. Generally, the larger the MTTF value, the longer the product can be used stably over time. [Contents] ■ What is MTTF, the indicator of product lifespan? ■ MTBF is used for repairable products ■ Common issues with MTTF and MTBF: the discrepancy between theoretical values and actual experience ■ Reference URL *For more details, please refer to the PDF document or feel free to contact us.
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This document introduces the specific methods and points of caution for conducting risk assessments in the workplace and during operations. "Risk assessment," which refers to the process of identifying, clarifying, and evaluating risks present in the field, is extremely important for the operation of machinery and systems. To achieve a truly safe workplace, it is necessary to conduct risk assessments based on extensive knowledge and the latest information. [Contents] ■ What is risk assessment? Check the methods and points of caution - The necessity of risk assessment - How to conduct a risk assessment - Points of caution in risk assessment ■ High risk! Risk assessment of control valves *For more details, please refer to the PDF document or feel free to contact us.
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This document introduces single point lockout as an effective means to achieve both safety and cost reduction. Single point lockout refers to the consolidation of multiple lockout points into one, allowing all machines to be stopped with a single lockout/tagout procedure. With this method, lockout/tagout can be completed with minimal time and effort, preventing workers from skipping the process. We encourage you to consider implementing this to enhance safety and efficiency in machine operations. [Contents] ■ Lockout/tagout to prevent human error ■ Single point lockout to further enhance safety efficiently ■ Reference sites *For more details, please refer to the PDF document or feel free to contact us.
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This document introduces the important topic of "residual pressure exhaust" for ensuring worker safety and efficient maintenance, along with examples. Residual pressure poses risks such as parts being blown off, workers tripping, and hazardous materials being ejected. To ensure worker safety, it is crucial not only to stop the pressure supply but also to thoroughly exhaust residual pressure. [Contents] ■ Unexpected accidents that can occur due to residual pressure ■ Residual pressure exhaust valves that help prevent accidents ■ Even when machines are stopped, do not let your guard down; ensure residual pressure exhaust ■ Reference sites *For more details, please refer to the PDF document or feel free to contact us.
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This document introduces the role of air blow in factories, its relationship with electricity, and the "pulse blow" method, which is expected to significantly improve efficiency. While air blow contributes to enhancing product quality, did you know that it actually consumes a large amount of electricity during operation? By reviewing and improving air blow systems, you can efficiently reduce the costs associated with electricity consumption. This also leads to energy savings and improvements in product quality. For the smooth operation of your factory, we encourage you to consider the introduction of pulse blow. [Contents] ■ Essential for product manufacturing! The role of air blow and its relationship with electricity ■ Also contributes to product quality improvement! The key points are "pressure" and "timing" - Reduction of air consumption - Improvement of blowing power through intermittent impact *For more details, please refer to the PDF document or feel free to contact us.
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This document introduces "monitor-equipped double valves" as an example of enhancing safety management standards. The monitor attached to the double valve has the function of detecting malfunctions and preventing restarts. If the press machine operates while malfunctioning, there is a possibility of accidents; however, the monitor can prevent accidents by cutting off the electrical and pneumatic circuits within the double valve. Our company offers a wide range of products that meet global standards, so if you have any concerns about safety, please feel free to consult us. [Contents] ■ The changing awareness of safety management in Japan ■ Comparison of safety management between the United States, Europe, and Japan ■ "Monitor-equipped double valves" that guarantee high safety *For more details, please refer to the PDF document or feel free to contact us.
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This document introduces how double valves with monitors ensure safety compared to conventional single valves and double valves without monitors. In the control valves of press machines, by introducing double valves with monitors, accidents that cannot be prevented by workers alone can be avoided, ensuring high safety. With our double valves, monitors can be retrofitted, so if you are using double valves without monitors, please consider upgrading to those with monitors to enhance safety. [Contents] ■ Differences between single valves and double valves without monitors during machine failures - ON failure - OFF failure ■ Differences between without monitor and with monitor *For more details, please refer to the PDF document or feel free to contact us.
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This document introduces the system of international standards such as ISO standards and IEC standards. As international safety standards for machinery and systems, there are ISO standards and IEC standards. These two standards target different fields; in the industrial sector, ISO standards pertain to mechanical systems, while IEC standards relate to electrical systems. Additionally, ISO/IEC Guide 51 divides ISO and IEC standards into three levels, allowing for a combination that can accommodate various products. [Contents] ■ International standards: ISO standards and IEC standards ■ Three standards in ISO/IEC Guide 51 - A standards - B standards ■ Reference URL *For more details, please refer to the PDF document or feel free to contact us.
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This document introduces the management of machine safety along with the "safety categories," which are closely related to the machine control system. Safety categories are important indicators for ensuring safety through machine control. By implementing and operating machines with high-level safety categories, it is possible to create a workplace that does not rely on human safety management. [Contents] ■ Overview of the "safety categories" that assess how safe a machine is - Safety Category 1 - Safety Category 2 - Safety Category 3 - Safety Category 4 ■ Reference sites *For more details, please refer to the materials on our company website or feel free to contact us. https://rossasia.co.jp/column/
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This document introduces examples of disaster costs arising from occupational accidents. When an occupational accident occurs, there are not only financial losses but also various issues such as a decline in corporate image, employee turnover, and decreased retention rates. Safety management to prevent accidents is related to various benefits for the company, so it is essential to pay careful attention and not neglect it. [Contents] ■ Direct costs paid to the victims ■ Indirect costs, which often exceed direct costs ■ Reference URL *For more details, please refer to the PDF document or feel free to contact us.
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The "HBB Series" is a redundant 3/2 valve system for external control that meets the needs and requirements for safe hydraulic shut-off and tank return for machines equipped with hydraulic control. By introducing a hydraulic double valve, not only is machine safety improved, but it also standardizes hydraulic safety solutions and simplifies complex circuit designs. The test port included in the double valve allows for quicker troubleshooting and reduces machine downtime, enabling improved operational efficiency and cost savings. 【Features】 ■ Shuts off hydraulic supply pressure and returns secondary side pressure to the tank ■ Equipped with a relief valve on the inlet side ■ Maximum flow rate is 50 gpm (189 l/min) *For more details, please refer to the PDF document or feel free to contact us.
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We would like to introduce our hydraulic shut-off and load-holding safety valve, the 'HBH Series.' In the event of a loss of supply pressure and/or power, it stops and holds the movement of the cylinder. By introducing a hydraulic double valve, we not only improve machine safety but also standardize hydraulic safety solutions, simplifying complex circuit designs. The test port included in the double valve allows for quicker troubleshooting and reduces machine downtime, enabling improved operational efficiency and cost savings. 【Features】 ■ Maximum flow rate: 145 gal/min (549 l/min) ■ Two body sizes: (D52, D32) ■ Port sizes: 1 1/2” and 2”, Code 62 Flange *For more details, please refer to the PDF document or feel free to contact us.
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The RSe series can be used for the following two types of applications by changing the base. (3/2) == The RSe series double valve is a redundant monitoring 3/2 valve. It is designed to meet the requirements necessary for safe air supply and exhaust applications in pneumatic control devices. (5/2) == The RSe series double valve is a redundant monitoring 5/2 valve. It is designed to meet the requirements necessary for safe cylinder control applications in pneumatic control devices.
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The M35 series valves are designed for safe and redundant valve operation with external monitoring. The valves are configured in a redundant, 3/2 poppet specification and feature the comprehensive functionality of pilot-operated single solenoid, spring return valves. Each single valve in the M35 series is equipped with solid-state pressure sensors. By monitoring both of these sensors during the operation and non-operation of the M35 valves, a diagnostic range of 99% is achieved. The monitoring of these sensors is conducted by an external monitoring system.
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1. Energy Isolation (Residual Pressure Treatment) 〇 Background and Purpose - Preventing accidents caused by residual pressure during maintenance ⇒ Safety against misoperation and unintended activation - Ensuring reliable energy isolation during emergency stops ⇒ Safety coordinated with power shutdown 〇 Related Standards - The U.S. OSHA "29CFR1910.147" stipulates energy isolation and ensures safety during maintenance through the following measures: ☆ Disconnecting power sources (electricity, pneumatic, hydraulic, etc.) ☆ Lock Out: Securing with a lock ☆ Tag Out: Clearly indicating the status with a tag. ☆ Systematizing using double valves. 2. Prevention of Ejection 〇 Background and Purpose - After releasing pressure in the pneumatic system, during the process of re-supplying pressure, a phenomenon of cylinder ejection may occur, potentially leading to disasters or equipment damage. 3. Fall Prevention 〇 Background and Purpose - During maintenance and emergency stops, while pneumatic energy isolation and residual pressure treatment are being performed, there can be problematic cases. In fall prevention for pneumatic cylinder lifting devices, particularly when heavy objects or sheet metal fall, it is required to consider the safety of workers and the prevention of equipment damage.
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ROSS provides a range of products specialized in safety, represented by items such as "L-O-X," "EEZ-ON," "P.O. Check," and "Double Valve," as well as application circuit technology for constructing pneumatic systems using these devices. When designing machinery, it is essential to implement inherently safe design strategies that anticipate mistakes and failures. A useful tool in this regard is risk assessment. This book explains pneumatic safety in machine safety. [Table of Contents] ■ Chapter 1 Safety of Control - It doesn't end with just electrical wiring. ■ Chapter 2 Lockout/Tagout (LOTO) and Energy Isolation ■ Chapter 3 ANSI Z244 - Monitored Power Systems ■ Chapter 4 Risk Assessment and Pneumatic Systems ■ Chapter 5 Q&A *Technical pamphlet available! *For more details, please visit our website for materials or feel free to contact us. https://rossasia.co.jp/column/
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The device is installed at the air entry point of each pneumatic circuit, allowing for the instant exhaust of residual pressure during maintenance or in the event of a malfunction. After completing the work, the operator removes the padlock with the key they possess and restores the air pressure (to prevent malfunction). The LOX valve with a soft start (anti-ejection function) gradually increases the downstream air pressure while transitioning to the fully open state during restart, preventing the sudden movement of driving equipment such as cylinders.
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ROSS provides a range of products specialized in safety, such as "L-O-X," "EEZ-ON," "P.O. Check," and "Double Valve," as well as application circuit technology for constructing pneumatic systems using these devices. When designing machinery, it is essential to implement inherently safe design measures that anticipate mistakes and failures. A useful tool in this process is risk assessment. At Ross, we identify hazards through risk assessment and determine the control categories for safety measures. We then configure the control system with corresponding devices. 【Features】 [DM2 C/E Series Double Valve] ○ Self-contained dynamic monitoring system ○ Equipped with status indicators ○ Compliance with standards ○ High-speed response and large exhaust capacity ○ Reliable poppet structure resistant to contamination For more details, please contact us or download the catalog.
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One of the important features of the ROSS double valve is that it has a duplex (dual mechanism) design. The ROSS double valve incorporates two independent 3/2 normally closed three-way valves into a single common body. Each of these two valve bodies is operated by its own dedicated 3/2 normally closed pilot valve. When both pilot valves are energized simultaneously, both main valve bodies operate at the same time. The probability of both valve bodies malfunctioning simultaneously in the same cycle is extremely low, ensuring higher safety compared to single valves. Additionally, this product is certified by BG at the highest safety level, Performance Level (PL) 'E'.
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